Conformal heat exchanger passage features for improved flow distribution

ABSTRACT

A heat exchanger arrangement includes walls defining at least two circuit passages for porting a first fluid, a first of the circuit passages defining a first passage length, and a second of the circuit passages defining a second passage length, the second passage length being different from the first passage length, the walls being in thermal communication with a second fluid while isolating the first fluid from the second fluid, at least one of the first circuit passage and the second circuit passage includes a flow control feature configured to decrease an imbalance in flow between the first circuit passage and the second circuit passage compared to if the flow control feature were not present.

BACKGROUND

The present disclosure relates to heat exchangers, and moreparticularly, to a conformal heat exchanger having features for improvedflow distribution.

Heat exchangers are well known in the aviation arts and in otherindustries for providing a compact, low-weight, and highly-effectivemeans of exchanging heat from a hot fluid to a cold fluid. Heatexchangers can be located in tight spaces, such as within the nacelle ofa gas turbine engine, where it is desirable to optimize spaceutilization. Accordingly, a conformal heat exchanger core can have anexterior geometry that conforms to an available installation envelope,thereby helping to optimize space utilization. For example, a conformalheat exchanger core that is located adjacent to a fan duct can have acurved conformal geometry. Although the conformal geometry of aconformal heat exchanger core is beneficial from a perspective of spaceutilization, the resulting non-uniformity (i.e., variation) in heatexchanger passage geometry can result in flow maldistribution across theheat exchanger core, thereby impacting the thermal and/or hydraulicperformance of the conformal heat exchanger as compared to that of aheat exchanger core of uniform geometry. Because of the desire to reduceflow maldistribution across a conformal heat exchanger core, there is aneed for balancing the flow through the passages in the conformal heatexchanger to help optimize the thermal and/or hydraulic performance ofthe conformal heat exchanger.

SUMMARY

A heat exchanger arrangement includes walls defining at least twocircuit passages for porting a first fluid, a first of the circuitpassages defining a first passage length, and a second of the circuitpassages defining a second passage length, the second passage lengthbeing different from the first passage length, the walls being inthermal communication with a second fluid while isolating the firstfluid from the second fluid, at least one of the first circuit passageand the second circuit passage includes a flow control featureconfigured to decrease an imbalance in flow between the first circuitpassage and the second circuit passage compared to if the flow controlfeature were not present.

A method of reducing an imbalance in flow impedance throughout a heatexchanger arrangement that includes walls defining at least two circuitpassages for porting a first fluid, a first of the circuit passagesdefining a first passage length, and a second of the circuit passagesdefining a second passage length, the second passage length beingdifferent from the first passage length, the walls being in thermalcommunication with a second fluid while isolating the first fluid fromthe second fluid. The method includes providing a flow control featurein at least one of the first circuit passages, the flow control featureconfigured to decrease an imbalance in flow between the first circuitpassage and the second circuit passage compared to if the flow controlfeature were not present

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective end view of a conformal heat exchanger corewith varying passage height.

FIG. 1B is an enlarged view of the conformal heat exchanger core shownin FIG. 1A taken near the inner radius.

FIG. 1C is an enlarged view of the conformal heat exchanger core shownin FIG. 1A taken near the outer radius.

FIG. 2A is a perspective end view of a second embodiment of a conformalheat exchanger core with varying passage width.

FIG. 2B is an enlarged view of the conformal heat exchanger core shownin FIG. 2A taken near the inner radius.

FIG. 2C is an enlarged view of the conformal heat exchanger core shownin FIG. 2A taken near the outer radius.

FIG. 3 is a cross-sectional top view of the conformal heat exchangercore shown in FIG. 1A taken at cut line 3-3 in FIG. 1, showingadditional flow control features.

FIG. 4 is a perspective end view of a third embodiment of a conformalheat exchanger core with varying fin wavelength and fin amplitude.

FIG. 5A is a cross-sectional radial side view of an inner radius flowpassage of the conformal heat exchanger core shown in FIG. 4 taken atcut line 5A-5A in FIG. 4.

FIG. 5B is a cross-sectional radial side view of an outer radius flowpassage of the conformal heat exchanger core shown in FIG. 4 taken atcut line 5B-5B in FIG. 4.

FIG. 6A is a perspective view showing fin geometry for straight fins.

FIG. 6B is a perspective view showing fin geometry for strip fins.

FIG. 6C is a perspective view showing fin geometry for louvered fins.

FIG. 6D is a perspective view showing fin geometry for pin fins.

DETAILED DESCRIPTION

FIG. 1A is a perspective end view of a conformal heat exchanger corewith varying passage height. FIG. 1B is an enlarged view of theconformal heat exchanger core shown in FIG. 1A taken near the innerradius. FIG. 1C is an enlarged view of the conformal heat exchanger coreshown in FIG. 1A taken near the outer radius. Shown in FIGS. 1A-1C areconformal core 10, inner radius edge 12, outer radius edge 14, coldlayers 16, hot layers 18, cold passages 20, and hot passages 22. Alsolabeled in FIGS. 1A-1C are passage height H, inner radius r1, and cutline 3-3. Conformal core 10 is an exemplary embodiment of a heatexchanger core that can be located in a curved installation envelope. Anexemplary curved installation envelope is outside of and adjacent to afan duct that is within the nacelle of a gas turbine engine. Innerradius edge 12 defines the inner boundary of conformal core 10, whichcan conform to an inner curved or circular geometry, with a fan ductbeing a non-limiting example. The curvature of inner radius edge 12 isdefined by inner radius r1. Outer radius edge 14 defines the outerboundary of conformal core 10, which can conform to an outer curved orcircular geometry, with a nacelle being a non-limiting example. Thecurvature of outer radius edge 14 is defined by an outer radius (notlabeled in FIG. 1A). Conformal core 10 includes alternating cold layers16 and hot layers 18. Individual cold layers 16 are numbered 16 a, 16 b,16 c, and 16 d, moving from inner radius edge 12 to outer radius edge 14as shown in FIG. 1A. Similarly, individual hot layers 18 are numbered 18a, 18 b, and 18 c, moving from inner radius edge 12 to outer radius edge14 as shown in FIG. 1A. In the illustrated embodiment, all cold layers16 have about the same width, being measured along an axis from innerradius edge 12 to outer radius edge 14. Similarly, all hot layers 18have about the same width, being measured along an axis from innerradius edge 12 to outer radius edge 14. Each cold layer 16 includes anumber of cold passages 20, and each hot layer 18 includes a number ofhot passages 22. The numbering of cold and hot passages 20, 22 isconsistent with the numbering of each respective cold and hot layer 16,18, as shown in FIG. 1A. For example, cold layer 16 a (i.e., beingnearest inner radius edge 12) includes a number of cold passages 20 a,cold layer 16 b includes a number of cold passages 20 b, and so on.Individual cold and hot passages 20, 22 have passage height H, as willbe described. When configured with as appropriate inlet and outletmanifold (not shown) for the cold layers 16 and hot layers 18,respectively, conformal core 10 can be a conformal heat exchanger thatcan be used to transfer heat between a cold working fluid flowingthrough cold layers 16 and a hot working fluid flowing through hotlayers 18. The cold and hot working fluids are fluidly isolated fromeach other, each having a source of pressure that causes fluid flowthrough the respective cold and hot layers. When operating as a heatexchanger, heat is said to flow from a hot working fluid to a coldworking fluid. The cold working fluid can be referred to as a firstfluid, and the hot working fluid can be referred to as a second fluid.The fluid phases of the cold and hot fluids are independent of eachother, with each being a liquid, a gas, and/or a combination of a liquidand a gas. Moreover, a fluid phase change in the cold and/or hot fluidscan occur in conformal core 10. The terms “cold” and “hot” are relativeone to the other. As used in different embodiments, conformal core 10can encounter temperatures ranging from near absolute zero (for example,in cryogenic distillation) to 1,000 deg. F. (538 deg. C.) or more (forexample, in gas turbine engine systems and related components).Moreover, “hot” and “cold” are used in this disclosure as descriptiveterms to refer to the various components that are associated with therespective first and second fluid circuits in conformal core 10, withoutimplying that particular temperatures or a temperature relationshipexists for those components during the manufacturing process of the heatexchanger core.

Referring to FIGS. 1A-1C, the flow length of a particular cold passage20 a (i.e., nearest inner radius edge 12) will be less than the flowlength of a particular cold passage 20 d (i.e., nearest outer radiusedge 14) because of the curved geometry of conformal core 10. It isknown in fluid mechanics that the flow impedance (i.e., resistance) of aparticular fluid passage is related to the flow length of thatparticular fluid passage (i.e., passage length). To compensate for theflow impedance mismatch and the resulting flow maldistribution thatwould otherwise occur, passage height H16 a of cold passages 20 a incold layer 16 a is less than passage height H16 b of cold passages 20 bin cold layer 16 b. Similarly, passage height H16 b of cold passages 20b in cold layer 16 b is less than passage height H16 c of cold passages20 c in cold layer 16 c, and so on. Accordingly, passage height H ofcold passages 20 is smallest nearest inner radius edge 12 (i.e., atinner radius r1), and passage height H of cold passages 20 is largestnearest outer radius edge 14. The smaller passage height H in coldpassages 20 having the shortest flow length as compared to cold passages20 having the longest flow length mitigates the flow maldistributionthat would otherwise exist across cold layers 16 in conformal core 10.In a similar manner, passage height H18 a of hot passages 22 a in hotlayer 18 a is less than passage height H18 b of hot passages 22 b in hotlayer 18 b, and so on. In the illustrated embodiment, there is norelationship between passage height H16 a, H16 b, etc. of cold passages20 and passage height H18 a, H16 b, etc. of hot passages 22. Varyingpassage height H across conformal core 10 can be described as providingimpedance matching across conformal core 10. The flow distributionthroughout cold layers 16 and hot layers 18 are independent of eachother because the cold and hot fluid circuits are fluidly isolated fromeach other. By mitigating flow maldistribution across cold layers 16and/or hot layers 18 (i.e., by impedance matching), the thermal and/orhydraulic performance of conformal core 10 is improved, thereby helpingoptimize the performance of conformal core 10 for a given installationenvelope. It is to be appreciated that conformal core 10 is illustrativeof a conformal heat exchanger core, with the numbers of cold and hotlayers 16, 18 being exemplary. In different embodiments, conformal core10 can include fewer or more than the illustrated number of cold and hotlayers 16, 18. In various embodiments, conformal core can have variousgeometries that are different than the illustrated embodiment.

FIG. 2A is a perspective end view of a second embodiment of a conformalheat exchanger core with varying passage width. FIG. 2B is an enlargedview of the conformal heat exchanger core shown in FIG. 2A taken nearthe inner radius. FIG. 2C is an enlarged view of the conformal heatexchanger core shown in FIG. 2A taken near the outer radius. Shown inFIGS. 2A-2C are conformal core 110, inner radius edge 112, outer radiusedge 114, cold layers 116, hot layers 118, cold passages 120, and hotpassages 122. Also labeled in FIGS. 2A-2C are passage width W and innerradius r1. Conformal core 110 is an exemplary embodiment of a heatexchanger core that can be located in a curved installation envelope,having a description that is substantially similar to that given abovein regard to FIGS. 1A-1C. Inner radius edge 112 defines the innerboundary of conformal core 110, with the curvature of inner radius edge112 is defined by inner radius r1. Outer radius edge 114 defines theouter boundary of conformal core 10, with the curvature of outer radiusedge is 14 is defined by an outer radius (not labeled in FIG. 2A).Conformal core 110 includes alternating cold layers 116 and hot layers118. Individual cold layers 116 are numbered 116 a, 116 b, 116 c, and116 d, moving from inner radius edge 112 to outer radius edge 114 asshown in FIG. 2A. Similarly, individual hot layers 118 are numbered 118a, 118 b, and 118 c, moving from inner radius edge 112 to outer radiusedge 114 as shown in FIG. 2A. Each cold layer 116 includes a number ofcold passages 120, and each hot layer 118 includes a number of hotpassages 122. The numbering of cold and hot passages 120, 122 isconsistent with the numbering of each respective cold and hot layer 116,118, as shown in FIG. 2A. For example, cold layer 116 a (i.e., beingnearest inner radius edge 112) includes a number of cold passages 120 a,cold layer 116 b includes a number of cold passages 120 b, and so on.All cold passages 120 have the same height as each other. Similarly, allhot passages 122 have the same height as each other.

The curved geometry of conformal core 110 is similar to that describedabove in regard to FIGS. 1A-1C. To mitigate flow maldistribution thatwould otherwise occur, passage width W116 a of cold passages 120 a incold layer 116 a is less than passage width W116 b of cold passages 120b in cold layer 116 b. Similarly, passage width W116 b of cold passages120 b in cold layer 116 b is less than passage width W116 c of coldpassages 120 c in cold layer 116 c, and so on. Accordingly, passagewidth W of cold passages 120 is smallest nearest inner radius edge 112(i.e., at inner radius r1), and passage width W of cold passages 120 islargest nearest outer radius edge 114. The smaller passage width W incold passages 120 having the shortest flow length as compared to coldpassages 120 having the longest flow length mitigates the flowmaldistribution that would otherwise exist across cold layers 116 inconformal core 110. In a similar manner, passage width W118 a of hotpassages 122 a in hot layer 118 a is less than passage width W118 b ofhot passages 122 b in hot layer 118 b, and so on. The varying of passagewidth W of conformal core 110 can be described as impedance matchingacross conformal core 110. In the illustrated embodiment, there is norelationship between passage widths W116 a, W116 b, etc. of coldpassages 120 and passage widths W118 a, W116 b, etc. of hot passages122. By mitigating flow maldistribution (i.e., by impedance matching)across cold layers 116 and/or hot layers 118, the thermal and/orhydraulic performance of conformal core 110 is improved, thereby helpingoptimize the performance of conformal core 110 for a given installationenvelope.

FIG. 3 is a cross-sectional top view of conformal core 10 shown in FIG.1A taken at cut line 3-3 in FIG. 1A, showing additional flow controlfeatures. Shown in FIG. 3 are conformal core 210, inner radius edge 212,outer radius edge 214, cold layers 216, hot layers 218, turbulators 226,228, and geometric center point 230. Also labeled in FIG. 3 are innerradius r1, outer radius r2, passage length S, and turbulator spacing T.The curved geometry of conformal core 210 is readily visible in FIG. 3,with inner radius edge 212 defining inner radius r1 with respect togeometric center point 230, and with outer radius edge 214 definingouter radius r2 with respect to geometric center point 230. Conformalcore 210 includes alternating cold layers 216 and hot layers 218, whichare configured to provide heat transfer from a hot working fluid to acold working fluid as was described above in regard to FIGS. 1-1C. Eachrespective cold layer 216 includes a number of cold passages 220, andeach respective hot layer 218 includes a number of hot passages 222. Thenumbering of cold layers 216 a, 216 b, 216 c, 216 d, of cold passages220 a, 220 b, 220 c, 220 d, of hot layers 218 a, 218 b, 218 c, and ofhot passages 222 a, 222 b, 222 c is similar to that described above inregard to FIG. 1A. Passage length S defines the mean arc length of aparticular cold or hot passage 220, 222. For conformal core 210 havingthe geometry of a circular arc as shown in FIG. 3, the relationship of aparticular passage length S relative to a radius r is readily apparent.Accordingly, passage length S216 a (i.e., corresponding to cold layer216 a near inner radius r1) is less than passage length S216 d (i.e.,corresponding to cold layer 216 d near outer radius r2).

For illustration simplicity, FIG. 3 is shown as being taken at cut line3-3 in FIG. 1A. It is to be noted that FIG. 1A is directed to conformalcore 10 having varying passage height H. The following description ofFIG. 3 is without regard to passage height H, as described above inregard to FIGS. 1A-1C. Referring to FIG. 3, each cold passage 220includes a number of turbulators 226 at recurring turbulator spacing T.Turbulators 226 are surface discontinuities along an interior surface(i.e. a wetted surface) of cold passages 220. Turbulators 226 interruptthe flow of the cold working fluid through the respective cold passages220, thereby causing turbulence while increasing the flow impedancethrough the respective cold passage. Turbulators 226 can also bereferred to as ridges, bumps, riblets, and surface discontinuities.Turbulator spacing T216 a defines the distance from one turbulator 226to the next in cold passage 220 a near inner radius r1, and turbulatorspacing T216 d measures the distance from one turbulator 226 to the nextin cold passage 220 d near outer radius r2. Similar measurements ofturbulator spacing T in other cold passages 220 can be defined (notlabeled in FIG. 3). Smaller values of turbulator spacing T (i.e., agreater number of turbulators 226 per unit passage length S) increasethe flow impedance through a particular cold passage 220. Accordingly,turbulator spacing T can be configured to balance flow impedance acrosscold layers 216. The smaller turbulator spacing T in cold passages 220having the shortest flow length (i.e., in cold layer 216 a near innerradius r1) as compared to cold passages 220 having the longest flowlength (i.e., in cold layer 216 d near outer radius r2) balances flowimpedance across cold layers 216, thereby mitigating the flowmaldistribution that would otherwise exist across cold layers 216 inconformal core 210. In the illustrated embodiment, turbulator spacing Tincreases radially through the cold circuit (i.e., cold layers 216) in adirection from inner radius r1 to outer radius r2.

The foregoing description of turbulators 226 in cold layers 216 alsoapplies to turbulators 228 in hot layers 218 (i.e., in hot passages222). The smaller turbulator spacing T in hot passages 222 having theshortest flow length (i.e., in hot layer 218 a near inner radius r1) ascompared to hot passages 222 having the longest flow length (i.e., inhot layer 218 d near outer radius r2) balances flow impedance across hotlayers 218, thereby mitigating the flow maldistribution that wouldotherwise exist across hot layers 218 in conformal core 210. In theillustrated embodiment, turbulator spacing T increases radially throughthe hot circuit (i.e., hot layers 218) in a direction from inner radiusr1 to outer radius r2. In the illustrated embodiment, there is not adefined relationship between turbulator spacing T for cold layers 216 ascompared to turbulator spacing T for hot layers 218, because the coldcircuit is fluidly isolated from the hot circuit. In the illustratedembodiment, the location of turbulator 226, 228 is on one side of aparticular cold or hot passage 220, 222. In some embodiments,turbulators 226, 228 can be located on an opposite side of a particularcold or hot passage 220, 222 than shown. In other embodiments,turbulators 226, 228 can be located on both sides of a particular coldand/or hot passage 220, 222. In yet other embodiments, one or more coldand/or hot passages 220, 222 can have no turbulators 226, 228.

Referring again to FIG. 3, turbulators 226 are depicted as having anapproximately uniform shape and size, with turbulator spacing T beingthe feature that varies from one cold layer 216 to the next. In variousembodiments, other features of turbulators 226 can vary across coldlayers 216 that affect flow through affected cold passages 220.Non-limiting examples of flow-affecting features include turbulatorheight (i.e., measuring the projection of a particular turbulator 226into a particular cold passage 220) and turbulator shape (e.g.,rectangular, triangular). Accordingly, in a particular embodiment,turbulators 226 are configured to create the greatest flow impedance perunit passage length S in cold passages 220 having the smallest passagelength S, and the least flow impedance per unit passage length S in coldpassages 220 having the largest passage length S, thereby matching flowimpedance across cold layers 216. The foregoing description ofturbulators 226 in cold layers 216 applies to turbulators 228 in hotlayers 218. In a particular embodiment, turbulators 228 are configuredto create the greatest flow impedance per unit passage length S in hotpassages 222 having the smallest passage length S, and the least flowimpedance per unit passage length S in hot passages 222 having thelargest passage length S, thereby matching flow impedance across hotlayers 218. In this way, flow maldistribution in both the cold circuitand the hot circuit of conformal core 210 can be mitigated, therebyoptimizing thermal and/or hydraulic performance of conformal core 210for a given installation envelope.

FIG. 4 is a perspective end view of a third embodiment of a conformalheat exchanger core with varying fin wavelength and fin amplitude. FIG.5A is a cross-sectional radial side view of an inner radius flow passageof the conformal heat exchanger core shown in FIG. 4 taken at cut line5A-5A in FIG. 4. FIG. 5B is a cross-sectional radial side view of anouter radius flow passage of the conformal heat exchanger core shown inFIG. 4 taken at cut line 5B-5B in FIG. 4. Shown in FIG. 4 are conformalcore 310, inner radius edge 312, outer radius edge 314, cold layers 316,hot layers 318, cold passages 320, and hot passages 322. Shown in FIGS.5A-5B are cold layer 316, cold passages 320, and fins 330. Also labeledin FIGS. 5A-5B are fin wavelength λ, and fin amplitude A.

Conformal core 310 is an exemplary embodiment of a heat exchanger corethat can be located in a curved installation envelope, having adescription that is substantially similar to that given above in regardto FIGS. 1A-1C. Inner radius edge 312 defines the inner boundary ofconformal core 310 associated with the inner radius (not labeled in FIG.4), and outer radius edge 314 defines the outer boundary of conformalcore 310 associated with the outer radius (not labeled in FIG. 4). Thedescriptions of the inner and outer radii (not labeled in FIG. 4) aresimilar to those provided above in regard to FIG. 3. Conformal core 310includes alternating cold layers 316 and hot layers 318. Individual coldlayers 316 are numbered 316 a, 316 b, 316 c, and 316 d, moving frominner radius edge 312 to outer radius edge 314 as shown in FIG. 4.Similarly, individual hot layers 318 are numbered 318 a, 318 b, and 318c, moving from inner radius edge 312 to outer radius edge 314 as shownin FIG. 4. Each cold layer 316 includes a number of cold passages 320,and each hot layer 318 includes a number of hot passages 322. Thenumbering of cold and hot passages 320, 322 is consistent with thenumbering of each respective cold and hot layer 316, 318, as shown inFIG. 4. In the illustrated embodiment, the widths (not labeled in FIG.4) of all cold layers 316 are about the same, and the heights (notlabeled in FIG. 4) of all cold passages 320 are about the same. Instead,flow impedance is matched across cold layers 316 by varying theconfiguration of fins 330, as shown in FIGS. 5A-5B. Cold fins 330 a arelocated in cold layer 316 a, located near inner radius edge 312. Any twoadjacent cold fins 330 a define a particular cold passage 320 a nearinner radius edge 312. Cold fins 330 a are sinuous (i.e., having asinusoidal shape) and are characterized as having fin wavelength λ1 andfin amplitude A1. Similarly, cold fins 330 d near outer radius edge 314define cold passages 320 d and are characterized as having wavelength λ2and fin amplitude A2. In the illustrated embodiment, fin wavelength λ1near inner radius edge 312 is less than fin wavelength λ2 near outerradius edge 314. Fin wavelength λ in cold layers 316 b and 316 c (notshown in FIGS. 5A-5B) are intermediate values between fin wavelengths λ1and λ2, such that fin wavelength λ increases radially through the coldcircuit (i.e., cold layers 316) in a direction from the inner radius tothe outer radius. Cold fins 330 can also be referred to as wavy fins.

In the illustrated embodiment, fin amplitude A1 near inner radius edge312 is greater than fin amplitude A2 near outer radius edge 314. Finamplitude A in cold layers 316 b and 316 c (not shown in FIGS. 5A-5B)are intermediate values between fin amplitudes A1 and A2, such that finamplitude A decreases radially through the cold circuit (i.e., coldlayers 316) in a direction from the inner radius to the outer radius.The cold working fluid flowing through cold passages 316 must follow asinuous path defined by fin 330, continuously changing direction whileflowing through cold passages 320. The shorter fin wavelength λ1 in coldlayer 316 a as compared to fin wavelength λ2 in cold layer 316 d causesmore frequent flow reversal per unit passage length, thereby resultingin greater flow impedance per unit passage length. Similarly, thegreater fin amplitude A1 in cold layer 316 a as compared to finamplitude A2 in cold layer 316 d causes a more dynamic flow reversal perunit passage length, thereby resulting in greater flow impedance perunit passage length. By varying fin wavelength λ and fin amplitude Aacross cold layers 316, flow impedance is matched across cold layers316, thereby mitigating flow maldistribution in the cold circuit. Theillustrated embodiment shows a variation in both fin wavelength λ andfin amplitude A across cold layers 316. In some embodiments, only oneparameter (i.e., fin wavelength λ or fin amplitude A) can vary.

The foregoing description of fins 330 in cold layers 316 can also beapplied to the hot fins (not shown) in hot layers 318. For example, finwavelength λ can vary across hot layers 318, such that a shorter valueof fin wavelength λ is in hot layer 318 a near the inner radius, and alonger value of fin wavelength λ is in hot layer 318 c near the outerradius. Similarly, fin amplitude A vary across hot layers 318, such thata larger value of fin amplitude A is in hot layer 318 a near the innerradius, and a smaller value of fin amplitude A is in hot layer 318 cnear the outer radius. By configuring the variation of fin wavelength λand/or fin amplitude A across hot layers 318, flow impedance is matchedacross hot layers 318, thereby mitigating flow maldistribution in thehot circuit. Accordingly, the distribution of fin wavelength λ and/orfin amplitude A in cold layers 316 and/or hot layers 318 can optimizingthe thermal and/or hydraulic performance of conformal core 310 for agiven installation envelope.

The various embodiments shown and described above in regard to FIGS.1A-1C, 2A-2C, 3-4, and 5A-5B are based on a conformal heat exchangercore having a geometry that surrounds a circular shape (e.g., a fanduct). FIGS. 1A, 2A, and 3-4 depict an approximately quarter-circulararc of a right circular cylinder for simplicity in illustrating thevarious impedance-matching features. All conformal heat exchanger coregeometries are within the scope of the present disclosure. For example,a particular conformal heat exchanger core can be either more than orless than a quarter-circular arc. The shape of a component the conformalheat exchanger core accommodates can be different than circular, withnon-limiting examples including oval, elliptical, square, rectangular,triangular, and the like. Moreover, the height of the conformal heatexchanger core (i.e., in a direction orthogonal to the inner and outerradius) can vary with the radius. In other words, the end view ofconformal core 10 depicted in FIG. 1A can be a non-rectangular shape.Non-limiting examples of non-rectangular shapes include trapezoidal,oval, and round shapes. For example, a conformal heat exchanger corehaving a toroidal shape will present a round cross-sectional end view.

The various embodiments shown and described above in regard to FIGS.1A-1C, 2A-2C, 3-4, and 5A-5B depict various means of matching flowimpedance in cold and hot circuits in a conformal heat exchanger corethat has a variation in passage length across the core. Various passagefeatures (i.e., flow control passage features) were disclosed, eachcontributing to impedance matching, thereby mitigating flowmaldistribution in a conformal heat exchanger core. In variousembodiments, any combination of the aforementioned passage features canbe used to provide flow impedance matching. Moreover, passage featuresin some passages and/or some layers can be different from those passagefeatures in other passages and/or layers. These flow control passagefeatures can also be referred to as flow control features,impedance-matching features, flow maldistribution mitigation features,and flow distribution improvement features. The list ofimpedance-matching features shown in FIGS. 1A-1C, 2A-2C, 3-4, and 5A-5Bis non-limiting, and all other impedance-matching features are withinthe scope of the present disclosure. Additional examples ofimpedance-matching features are further disclosed, as follows.

FIG. 6A is a perspective view showing fin geometry for straight fins.Shown in FIG. 6A are straight fins 430. Also labeled in FIG. 6A are finheight FH and fin pitch FP. In an embodiment using straight fins 430,fin height FH and/or fin pitch FP can be varied throughout a conformalheat exchanger core to provide impedance matching, thereby mitigatingflow maldistribution throughout the conformal heat exchanger core.

FIG. 6B is a perspective view showing fin geometry for strip fins. Shownin FIG. 6B are strip fins 530. Also labeled in FIG. 6A are offset lengthOL and offset height OH. In an embodiment using strip fins 530, offsetlength OL and/or offset height OH can be varied throughout a conformalheat exchanger core to provide impedance matching, thereby mitigatingflow maldistribution throughout the conformal heat exchanger core.

FIG. 6C is a perspective view showing fin geometry for louvered fins.Shown in FIG. 6C are louvered fins 630 and louvers 632. Also labeled inFIG. 6C are louver spacing LS and louver gap LG. In an embodiment usinglouvered fins 630, louver spacing LS and/or louver gap LG can be variedthroughout a conformal heat exchanger core to provide impedancematching, thereby mitigating flow maldistribution throughout theconformal heat exchanger core.

FIG. 6D is a perspective view showing fin geometry for pin fins. Shownin FIG. 6D are pin fins 730 and pins 732. Also labeled in FIG. 6D arecross-stream spacing CS, downstream spacing DS, and pin height PH.Smaller values of cross-stream spacing CS and/or downstream spacing DSprovide a greater value of pin density, with a larger value of pindensity generally providing greater flow impedance. Larger values of pinheight PH also generally provide greater flow impedance. In anembodiment using pin fins 730, pin density (i.e., cross-stream spacingCS and/or downstream spacing DS) and/or pin height PH can be variedthroughout a conformal heat exchanger core to provide impedancematching, thereby mitigating flow maldistribution throughout theconformal heat exchanger core.

In describing the various flow control features in FIGS. 1A-1C, 2A-2C,3-4, 5A-5B, and 6A-6D, reference was made to various passages bycomparing a passage near an inner radius to a passage further from theinner radius (i.e., closer to the outer radius). The various passagescan also be referred to as circuits. Accordingly, a comparison can bemade between a first circuit passage and a second circuit passage,whereby both circuits port the same working fluid (i.e., the first orsecond fluid).

The various embodiments shown and described in the present disclosureare directed to various structures that can be used to provideimpedance-matching in conformal core 10, 110, 210, 310. Accordingly,methods of providing impedance-matching can be achieved by utilizing theforegoing structures. All means of fabricating conformal core 10, 110,210, 310 to provide various impedance-matching features are within thescope of the present disclosure, with non-limiting examples includingbrazing, welding, extrusion, casting, machining, subtractive, additive,hybrid-additive, and additive-subtractive manufacturing processes. Insome embodiments, the various impedance-matching features of the presentdisclosure can be suitable to an additive manufacturing process.Moreover, an additive manufacturing process can lend itself to themanufacturing of a conformal heat exchanger core in some embodiments.Accordingly, conformal core 10, 110, 210, 310 can be made from amaterial that is suitable for a particular application and/or aparticular manufacturing process. In various embodiments, conformal core10, 110, 210, 310 can be made of aluminum, copper, nickel, titanium,iron, cobalt, or any alloy of one or more of these metals. In otherembodiments, conformal core 10, 110, 210, 310 can be made of any metaland/or non-metal. Exemplary non-metals include polymers (e.g.,polypropylene, polyethylene, polyphenylene sulfide (PPS), andpolytetrafluoroethylene (PTFE)). In yet other embodiments, conformalcore 10, 110, 210, 310 can be made of polymer composites, for example,any of the aforementioned polymers filled with graphite, metallicparticles, carbon fibers, and/or carbon nanotubes. Laser powder bedfusion (LPBF) is a non-limiting exemplary additive-manufacturing processthat can be used to manufacture conformal core 10, 110, 210, 310. Insome embodiments of a LPBF additive manufacturing process, variousalloys of INCONEL™ can be used, with Inconel 625 and Inconel 718 beingtwo exemplary alloy formulations. In other embodiments, othernickel-based superalloys can be used, with Haynes 282™ being an example.In yet other embodiments, alloys of aluminum can be used. For example,alloys of aluminum known as A205, A20X™ AlSi10Mg, and Aluminum 6061 canbe used.

Discussion of Possible Embodiments

The following are non-exclusive descriptions of possible embodiments ofthe present invention.

A heat exchanger arrangement comprising: walls defining at least twocircuit passages for porting a first fluid, a first of the circuitpassages defining a first passage length, and a second of the circuitpassages defining a second passage length, the second passage lengthbeing different from the first passage length, the walls being inthermal communication with a second fluid while isolating the firstfluid from the second fluid, at least one of the first circuit passageand the second circuit passage includes a flow control featureconfigured to decrease an imbalance in flow between the first circuitpassage and the second circuit passage compared to if the flow controlfeature were not present.

The heat exchanger arrangement of the preceding paragraph can optionallyinclude, additionally and/or alternatively, any one or more of thefollowing features, configurations and/or additional components:

A further embodiment of the foregoing heat exchanger arrangement,wherein at least the first circuit passage and the second circuitpassage are configured in a curved geometry defining an inner radius andan outer radius, the inner radius being smaller than the outer radius.

A further embodiment of the foregoing heat exchanger arrangement,wherein: the first circuit passage is disposed in a region of the heatexchanger arrangement proximate the inner radius; and the flow controlfeature is included in the first circuit passage.

A further embodiment of the foregoing heat exchanger arrangement,wherein the flow control feature is a difference in fin spacing,wherein: the fin spacing in the first circuit passage is less than thefin spacing in the second circuit passage; and the fin spacing in thefirst circuit passage is configured to restrict flow therethrough,thereby increasing a flow impedance in the first circuit passage.

A further embodiment of the foregoing heat exchanger arrangement,wherein the flow control feature is a difference in fin height, wherein:the fin height in the first circuit passage is less than the fin heightin the second circuit passage; and the fin height in the first circuitpassage is configured to restrict flow therethrough, thereby increasinga flow impedance in the first circuit passage.

A further embodiment of the foregoing heat exchanger arrangement,wherein: the first and second circuit passages each further comprisestwo or more turbulators; two adjacent turbulators in the first circuitpassage defining a respective first circuit passage turbulator spacingdensity; two adjacent turbulators in the second circuit passage defininga respective second circuit passage turbulator spacing density; the flowcontrol feature is a difference between first circuit passage turbulatorspacing density and the second circuit passage turbulator spacingdensity; the first circuit turbulator spacing density is greater thanthe second circuit turbulator spacing density; and the first circuitturbulator spacing is configured to restrict flow therethrough, therebyincreasing the flow impedance in the first circuit passage.

A further embodiment of the foregoing heat exchanger arrangement,wherein: the first and second circuit passages each further compriseswavy fins; the wavy fins define wavy fin characteristics of finamplitude and fin wavelength; the flow control feature is a differencefin amplitude; and the fin amplitude in the first circuit passage isgreater than the fin amplitude in the second circuit passage.

A further embodiment of the foregoing heat exchanger arrangement,wherein: the first and second circuit passages each further compriseswavy fins; the wavy fins define wavy fin characteristics of finamplitude and fin wavelength; the flow control feature is a differencefin wavelength; and the fin wavelength in the first circuit passage isless than the fin wavelength in the second circuit passage.

A further embodiment of the foregoing heat exchanger arrangement,wherein: the flow control feature is a variation in a fin feature; thevariation in the fin feature is selected from the group consisting of:straight fins, strip fins, louvered fins, and pin fins; and thevariation in the fin feature is configured to restrict a flow throughthe first circuit passage as compared to the fin feature in the secondcircuit passage, thereby increasing the flow impedance of the firstcircuit passage.

A further embodiment of the foregoing heat exchanger arrangement,wherein: the first and second circuit passages each define across-sectional flow area; the flow control feature is a difference inthe cross-sectional flow area; the cross-sectional flow area in thefirst circuit passage is smaller than the cross-sectional flow area inthe second circuit passage; and the smaller cross-sectional flow area inthe first circuit passage is configured to restrict flow therethrough,thereby increasing the flow impedance in the first circuit passage.

A further embodiment of the foregoing heat exchanger arrangement,further comprising two or more second fluid passages for porting thesecond fluid, defining at least a second fluid first circuit passage anda second fluid second circuit passage, wherein: the second fluid firstcircuit passage defines a second circuit first passage length; thesecond fluid second circuit passage defines a second circuit secondpassage length, the second circuit second passage length being greaterthan the second fluid first circuit passage; and at least the secondfluid first circuit passage includes a second fluid flow control featureconfigured to decrease an imbalance in flow between the second fluidfirst circuit passage and the second fluid second circuit passagecompared to if the second fluid flow control feature were not present.

A further embodiment of the foregoing heat exchanger arrangement,comprising a material selected from the group consisting of nickel,aluminum, titanium, copper, iron, cobalt, or alloys thereof.

A further embodiment of the foregoing heat exchanger arrangement,comprising one or more polymers selected from the group consisting ofpolypropylene, polyethylene, polyphenylene sulfide (PPS), andpolytetrafluoroethylene (PTFE).

A further embodiment of the foregoing heat exchanger arrangement,wherein the heat exchanger arrangement is made using an additivemanufacturing process.

A further embodiment of the foregoing heat exchanger arrangement,wherein: the heat exchanger arrangement is a conformal heat exchangercore; and the conformal heat exchanger core is configured to conform toan outer portion of a circular shape.

A method of reducing an imbalance in flow impedance throughout a heatexchanger arrangement comprising walls defining at least two circuitpassages for porting a first fluid, a first of the circuit passagesdefining a first passage length, and a second of the circuit passagesdefining a second passage length, the second passage length beingdifferent from the first passage length, the walls being in thermalcommunication with a second fluid while isolating the first fluid fromthe second fluid, the method comprising: including a flow controlfeature in at least one of the first circuit passages, the flow controlfeature configured to decrease an imbalance in flow between the firstcircuit passage and the second circuit passage compared to if the flowcontrol feature were not present.

The method of the preceding paragraph can optionally include,additionally and/or alternatively, any one or more of the followingfeatures, configurations and/or additional components:

A further embodiment of the foregoing method, wherein: at least thefirst circuit passage and the second circuit passage are configured in acurved geometry defining an inner radius and an outer radius, the innerradius being smaller than the outer radius; the first circuit passage isdisposed in a region of the heat exchanger arrangement proximate theinner radius; and the flow control feature is included in the firstcircuit passage.

A further embodiment of the foregoing method, wherein the flow controlfeature comprises one or more of: a difference in fin spacing, wherein:the fin spacing in the first circuit passage is less than the finspacing in the second circuit passage; and the fin spacing in the firstcircuit passage is configured to restrict flow therethrough, therebyincreasing the flow impedance thereof; and a difference in fin height,wherein: the fin height in the first circuit passage is less than thefin height in the second circuit passage; and the fin height in thefirst circuit passage is configured to restrict flow therethrough,thereby increasing the flow impedance thereof.

A further embodiment of the foregoing method, wherein: the first andsecond circuit passages each further comprises two or more turbulators;two adjacent turbulators in the first circuit passage defining arespective first circuit passage turbulator spacing density; twoadjacent turbulators in the second circuit passage defining a respectivesecond circuit passage turbulator spacing density; the flow controlfeature is a difference between first circuit passage turbulator spacingdensity and the second circuit passage turbulator spacing density; thefirst circuit turbulator spacing density is greater than the secondcircuit turbulator spacing density; and the first circuit turbulatorspacing is configured to restrict flow therethrough, thereby increasingthe flow impedance in the first circuit passage.

A further embodiment of the foregoing method, wherein: the first andsecond circuit passages each further comprise wavy fins; the wavy finsdefine wavy fin characteristics of fin amplitude and fin wavelength; andthe flow control feature comprises one or more of: a difference in finamplitude, wherein the fin amplitude in the first circuit passage isgreater than the fin amplitude in the second circuit passage; and adifference in fin wavelength, wherein the fin wavelength in the firstcircuit passage is less than the fin wavelength in the second circuitpassage.

While the invention has been described with reference to an exemplaryembodiment(s), it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment(s) disclosed, but that theinvention will include all embodiments falling within the scope of theappended claims.

The invention claimed is:
 1. A heat exchanger arrangement comprising:walls defining at least two circuit passages for porting a first fluid,a first of the circuit passages defining a first passage length, and asecond of the circuit passages defining a second passage length, thesecond passage length being different from the first passage length,wherein the first of the circuit passages is directly adjacent to thesecond of the circuit passages; wherein the walls are being in thermalcommunication with a second fluid while isolating the first fluid fromthe second fluid, such that the first fluid and the second fluid flow inthe same direction; and wherein at least one of the first circuitpassage and the second circuit passage includes a flow control featureconfigured to decrease an imbalance in flow between the first circuitpassage and the second circuit passage.
 2. The heat exchangerarrangement of claim 1, wherein at least the first circuit passage andthe second circuit passage are configured in a curved geometry definingan inner radius and an outer radius, the inner radius being smaller thanthe outer radius.
 3. The heat exchanger arrangement of claim 2, wherein:the first circuit passage is disposed in a region of the heat exchangerarrangement proximate the inner radius; and the flow control feature isincluded in the first circuit passage.
 4. The heat exchanger arrangementof claim 3, wherein the flow control feature is a difference in finspacing, wherein: the fin spacing in the first circuit passage is lessthan the fin spacing in the second circuit passage; and the fin spacingin the first circuit passage is configured to restrict flowtherethrough, thereby increasing a flow impedance in the first circuitpassage.
 5. The heat exchanger arrangement of claim 3, wherein the flowcontrol feature is a difference in fin height, wherein: the fin heightin the first circuit passage is less than the fin height in the secondcircuit passage; and the fin height in the first circuit passage isconfigured to restrict flow therethrough, thereby increasing a flowimpedance in the first circuit passage.
 6. The heat exchangerarrangement of claim 3, wherein: the first and second circuit passageseach further comprises two or more turbulators; two adjacent turbulatorsin the first circuit passage defining a respective first circuit passageturbulator spacing density; two adjacent turbulators in the secondcircuit passage defining a respective second circuit passage turbulatorspacing density; the flow control feature is a difference between firstcircuit passage turbulator spacing density and the second circuitpassage turbulator spacing density; the first circuit turbulator spacingdensity is greater than the second circuit turbulator spacing density;and the first circuit turbulator spacing is configured to restrict flowtherethrough, thereby increasing the flow impedance in the first circuitpassage.
 7. The heat exchanger arrangement of claim 3, wherein: thefirst and second circuit passages each further comprises wavy fins; thewavy fins define wavy fin characteristics of fin amplitude and finwavelength; the flow control feature is a difference fin amplitude; andthe fin amplitude in the first circuit passage is greater than the finamplitude in the second circuit passage.
 8. The heat exchangerarrangement of claim 3, wherein: the first and second circuit passageseach further comprises wavy fins; the wavy fins define wavy fincharacteristics of fin amplitude and fin wavelength; the flow controlfeature is a difference fin wavelength; and the fin wavelength in thefirst circuit passage is less than the fin wavelength in the secondcircuit passage.
 9. The heat exchanger arrangement of claim 3, wherein:the flow control feature is a variation in a fin feature; the variationin the fin feature is selected from the group consisting of: straightfins, strip fins, louvered fins, and pin fins; and the variation in thefin feature is configured to restrict a flow through the first circuitpassage as compared to the fin feature in the second circuit passage,thereby increasing the flow impedance of the first circuit passage. 10.The heat exchanger arrangement of claim 3, wherein: the first and secondcircuit passages each define a cross-sectional flow area; the flowcontrol feature is a difference in the cross-sectional flow area; thecross-sectional flow area in the first circuit passage is smaller thanthe cross-sectional flow area in the second circuit passage; and thesmaller cross-sectional flow area in the first circuit passage isconfigured to restrict flow therethrough, thereby increasing the flowimpedance in the first circuit passage.
 11. The heat exchangerarrangement of claim 1, further comprising two or more second fluidpassages for porting the second fluid, defining at least a second fluidfirst circuit passage and a second fluid second circuit passage,wherein: the second fluid first circuit passage defines a second circuitfirst passage length; the second fluid second circuit passage defines asecond circuit second passage length, the second circuit second passagelength being greater than the second fluid first circuit passage; and atleast the second fluid first circuit passage includes a second fluidflow control feature configured to decrease an imbalance in flow betweenthe second fluid first circuit passage and the second fluid secondcircuit passage compared to if the second fluid flow control featurewere not present.
 12. The heat exchanger arrangement of claim 1,comprising a material selected from the group consisting of nickel,aluminum, titanium, copper, iron, cobalt, or alloys thereof.
 13. Theheat exchanger arrangement of claim 1, comprising one or more polymersselected from the group consisting of polypropylene, polyethylene,polyphenylene sulfide (PPS), and polytetrafluoroethylene (PTFE).
 14. Theheat exchanger arrangement of claim 1, wherein the heat exchangerarrangement is made using an additive manufacturing process.
 15. Theheat exchanger arrangement of claim 1, wherein: the heat exchangerarrangement is a conformal heat exchanger core; and the conformal heatexchanger core is configured to conform to an outer portion of acircular shape.
 16. A method of reducing an imbalance in flow impedancethroughout a heat exchanger arrangement comprising walls defining atleast two circuit passages for porting a first fluid, a first of thecircuit passages defining a first passage length, and a second of thecircuit passages defining a second passage length, the second passagelength being different from the first passage length, the first of thecircuit passages being directly adjacent to the second of the circuitpassages, the walls being in thermal communication with a second fluidwhile isolating the first fluid from the second fluid, the methodcomprising: flowing the first fluid and the second fluid in a firstdirection through the heat exchanger; and decreasing an imbalance inflow between the first circuit passage and the second circuit passage byflowing the first fluid adjacent a flow control feature within at leastone of the first circuit passages, compared to if the flow controlfeature were not present.
 17. The method of claim 16, wherein: at leastthe first circuit passage and the second circuit passage are configuredin a curved geometry defining an inner radius and an outer radius, theinner radius being smaller than the outer radius; the first circuitpassage is disposed in a region of the heat exchanger arrangementproximate the inner radius; and the flow control feature is included inthe first circuit passage.
 18. The method of claim 16, wherein the flowcontrol feature comprises one or more of: a difference in fin spacing,wherein: the fin spacing in the first circuit passage is less than thefin spacing in the second circuit passage; and the fin spacing in thefirst circuit passage is configured to restrict flow therethrough,thereby increasing the flow impedance thereof; and a difference in finheight, wherein: the fin height in the first circuit passage is lessthan the fin height in the second circuit passage; and the fin height inthe first circuit passage is configured to restrict flow therethrough,thereby increasing the flow impedance thereof.
 19. The method of claim16, wherein: the first and second circuit passages each furthercomprises two or more turbulators; two adjacent turbulators in the firstcircuit passage defining a respective first circuit passage turbulatorspacing density; two adjacent turbulators in the second circuit passagedefining a respective second circuit passage turbulator spacing density;the flow control feature is a difference between first circuit passageturbulator spacing density and the second circuit passage turbulatorspacing density; the first circuit turbulator spacing density is greaterthan the second circuit turbulator spacing density; and the firstcircuit turbulator spacing is configured to restrict flow therethrough,thereby increasing the flow impedance in the first circuit passage. 20.The method of claim 16, wherein: the first and second circuit passageseach further comprise wavy fins; the wavy fins define wavy fincharacteristics of fin amplitude and fin wavelength; and the flowcontrol feature comprises one or more of: a difference in fin amplitude,wherein the fin amplitude in the first circuit passage is greater thanthe fin amplitude in the second circuit passage; and a difference in finwavelength, wherein the fin wavelength in the first circuit passage isless than the fin wavelength in the second circuit passage.